Contractors' Safety for Ammunition and Explosives, 16038-16077 [05-5429]

Agencies

• Office of the Secretary
• DEPARTMENT OF DEFENSE

[Federal Register Volume 70, Number 59 (Tuesday, March 29, 2005)]
[Proposed Rules]
[Pages 16038-16077]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 05-5429]



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Part III





Department of Defense





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Office of the Secretary



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32 CFR Part 184



Contractors' Safety for Ammunition and Explosives; Proposed Rule

Federal Register / Vol. 70, No. 59 / Tuesday, March 29, 2005 / 
Proposed Rules

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DEPARTMENT OF DEFENSE

Office of the Secretary

32 CFR Part 184

RIN 0790-AH76

[DoD 4145.26-M]


Contractors' Safety for Ammunition and Explosives

AGENCY: Office of the Secretary of Defense.

ACTION: Proposed rule for comment.

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SUMMARY: The Department of Defense (DoD) is codifying its revised 
explosives safety standards for ammunition and explosives (A&E) work 
performed under DoD contracts. This proposed rule is necessary to 
minimize the potential for mishaps that could interrupt DoD operations, 
delay project completion dates, adversely impact DoD production base or 
capability, damage or destroy DoD-owned material/equipment, cause 
injury to DoD personnel, or endanger the general public. The benefits 
of this proposed rule in terms of the protection of the public and 
ensuring contract performance are expected to balance its potential 
cost or administrative impacts. Only provisions related to conventional 
AE operations have been included in this proposed rule. No attempt was 
made to encompass general industrial safety, occupational health 
concerns, chemical warfare agents, radiation, or over-the-road 
transportation requirements, because these are either the 
responsibility of other regulatory agencies (for example DOT, DOL/OSHA, 
or NRC) or may be addressed elsewhere in the contract by the procuring 
activity. Budgetary effects of this proposed rule are minimal since 
existing DoD Federal Acquisition Regulation Supplement coverage already 
requires compliance with safety requirements in AE solicitations and 
contracts. Finally, because this proposed rule is needed to minimize 
the potential for AE mishaps that could adversely impact DoD and the 
public, timely publication in the Federal Register is important.

DATES: Comments are to be received not later than May 31, 2005.

FOR FURTHER INFORMATION CONTACT: Dr. Jerry M. Ward, Director, Engineer 
Technical Programs Division, DDESB, telephone (703) 325-2525, fax: 
(703) 325-6227; e-mail: Jerry.Ward@DDESB.OSD.mil.

SUPPLEMENTARY INFORMATION: Pursuant to the authority vested in the 
Secretary of Defense in accordance with 10 U.S.C. 172, DoD Directive 
6055.9 established the Department of Defense Explosives Safety Board as 
a joint activity of the Department of Defense subject to the direction, 
authority and control of the Secretary of Defense. The majority of the 
standards impacting upon the public were adopted prior to the enactment 
of the Administrative Procedure Act. This proposed rule is intended to 
ensure public awareness of the extent of the explosives safety 
standards as well as offer the public an opportunity to comment on the 
standards. The information addresses the HCSDS sometimes furnished with 
solicitations or contracts to provide an insight into potentially 
hazardous characteristics of the materials involved in the production 
of the item addressed in the solicitation. Contractors retain the 
ultimate responsibility for assuring the safety of their personnel and 
establishment. Information provided by the HCSDS is derived from other 
sources. Verification of such data as shipping and storage hazard 
division and storage compatibility group information must be done 
through the DoD Joint Hazard Classification System (JHCS) or Title 49, 
Code of Federal Regulations.
    These classifications pertain to AE packaged for transportation or 
storage. Such hazard classification information may not be valid when 
applied to the hazards associated with manufacturing or loading 
processes. For such processes, the materials and processes must be 
analyzed on a case-by-case basis. Sources of information to support 
this analysis are available from service research and development 
organizations through contract channels and other sources.

Executive Order 12866

    This proposed rule does not:
    (1) Have an annual effect of the economy of $100 million or more or 
adversely affect in a material way the economy, a sector of the 
economy, productivity, competition, jobs, the environment, public 
health or safety, or state, local, or tribal governments.
    (2) Create a serious inconsistency or otherwise interfere with an 
action taken or planned by another agency.
    (3) Materially alter the budgetary impact of entitlement, grants, 
user fees, or loan programs or the rights and obligations of recipients 
thereof; or
    (4) Raise novel legal or policy issues arising out of legal 
mandates, the President's priorities, or the principles set forth in 
this Executive Order.

Regulatory Flexibility Act of 1980 (5 U.S.C. 605(b))

    Regulatory Flexibility Act. It has been certified that this 
proposed rule, if promulgated, shall be exempt from the requirements 
under 5 U.S.C. 601-612. This proposed rule does not have a significant 
economic impact on small entities as defined in the Act.

Unfunded Mandates Act of 1995 (Sec. 202, Pub. L. 104-4)

    This proposed regulatory action does not contain a Federal mandate 
that will result in the expenditure by State, local, and tribal 
governments, in aggregate, or by the private sector of $100 million or 
more in any one year.

Paperwork Reduction Act of 1995 (44 U.S.C. Chapter 35)

    Paperwork Reduction Act. The proposed rule imposes no obligatory 
information requirements beyond internal Department of Defense needs.

Federalism (Executive Order 13132)

    This proposed regulatory action does not have federalism 
implications, as set forth in Executive Order 13132. It will not have 
substantial direct effects on the States, on the relationship between 
the national government and the States, or on the distribution of power 
and responsibilities among the various levels of government.

Section 202, Public Law 104-4, ``Unfunded Mandates Reform Act''

    It has been determined that this rule does not involve a Federal 
mandate that may result in the expenditure by State, local and tribal 
governments, in the aggregate, or by the private sector, of $100 
million or more and that such rulemaking will not significantly or 
uniquely affect small governments.

List of Subjects in 32 CFR Part 184

    Ammunition and explosives, DoD contractors.
    Accordingly, 32 CFR part 184 is proposed to be added to read as 
follows:

PART 184--DOD CONTRACTORS' SAFETY MANUAL

Sec.
184.1 Introduction.
184.2 Mishap investigation and reporting.
184.3 General safety requirements.
184.4 Quantity-distance and siting.
184.5 Hazard classification, storage principles, and compatibility 
groups.
184.6 Electrical safety requirements for AE facilities.
184.7 Manufacturing and processing propellants.
184.8 Safety requirements for manufacturing and processing 
pyrotechnics.
184.9 Storage of ammunition and explosives.
184.10 Fire protection.
184.11 Risk identification and management.

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184.12 AE building design and layout.
184.13 Safety requirements for specific AE and AE operations.
184.14 Test and testing requirements.
184.15 Collection and destruction requirements for AE.
184.16 Construction and siting criteria.
Appendix A to 32 CFR Part 184--Glossary


    Authority: 10 U.S.C. 172.


Sec.  184.1  Introduction.

    (a) Purpose. This part provides safety requirements, guidance and 
information to minimize potential mishaps which could interrupt 
Department of Defense (DoD) operations, delay production, damage DoD 
property, cause injury to DoD personnel, or endanger the public during 
contract work or services involving ammunition and explosives (AE). The 
part contains the minimum contractual safety requirements to support 
the objectives of DoD. These requirements are not a complete safety 
program and this part does not relieve a contractor from complying with 
Federal, State and local laws and regulations.
    (b) Applicability. These safety requirements apply to contractors 
performing AE work or AE services on DoD contracts, subcontracts, 
purchase orders, or other procurement methods. The requirements also 
apply to non-DoD contractor operations to the extent necessary to 
protect DoD work or services.
    (c) Mandatory and advisory requirements. The part uses the term 
``shall'', or an affirmative statement, to indicate mandatory 
requirements. The terms ``should'' and ``may'' are advisory. When 
advisory provisions are not met, adverse consequences might develop and 
become proximate causes of AE mishaps.
    (d) Compliance with mandatory requirements. (1) The Department of 
Defense requires compliance with mandatory provisions of this part and 
applicable portions of DoD 6055.9-STD.\1\ Siting criteria for AE are 
provided in quantity distance (Q-D) standards contained in Chapter 9 of 
DoD 6055.9-STD. In order to provide consistent and current information 
to all DoD AE contractors, Q-D requirements of DoD 6055.9-STD are 
incorporated by reference in paragraph C317.
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    \1\ Copies may be obtained via Internet at https://www.dtic.mil/
whs/directives.
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    (2) Waivers. Procuring contracting officers (PCO) may grant 
contract-specific waivers to mandatory provisions of this part. 
Rationale for waiver of DoD pre-award safety surveys must be documented 
and provided to the cognizant ACO for transmittal to the cognizant DoD 
Component explosives safety office for their records. Military or 
commercial ammunition and explosives shall not be procured unless their 
use is authorized by the cognizant DoD Component explosives safety 
approval authority. Methods of addressing non-compliance with mandatory 
requirements and requests for waivers are different during the pre- and 
post-award phases of a contract.
    (3) In the pre-award phase, the PCO will request a DoD pre-award 
safety survey to help determine contractor capability. During pre-award 
surveys, noncompliance with mandatory safety requirements normally 
results in a recommendation of ``no award.'' Any noncompliance should 
be resolved during the pre-award survey. Contractors may choose to 
correct the deficiencies immediately, may offer a letter of intent to 
correct the deficiencies (which will become binding upon award of 
contract), or may request that the PCO accept specifically identified 
existing conditions of facilities (contract-specific waiver).
    (4) In the post-award phase, the contractor has 30 days from the 
date of notification by the administrative contracting officer (ACO) to 
correct the noncompliance and inform the ACO of the corrective actions 
taken. The contracting officer may direct a different time period for 
the correction of any noncompliance. If the contractor refuses or fails 
to correct any noncompliance within the time period specified by the 
ACO, the Government has the right to direct the contractor to cease 
performance on all or part of affected contracts. When the contractor 
cannot comply with the mandatory safety requirements of the contract, 
the contractor will develop and submit a request for a waiver through 
the ACO to the PCO for the final determination. The request will 
contain complete information concerning the requirements violated, 
actions planned to minimize the hazard, and a proposed date for 
correction of the deficiency.
    (e) Pre-award safety survey. DoD safety personnel conduct pre-award 
surveys to evaluate each prospective contractor's ability to comply 
with contract safety requirements. The pre-award safety survey is also 
an opportunity for the contractor to request clarification of any 
safety requirement or other AE issue that may affect the contractor's 
ability to comply. During pre-award surveys, the contractor shall 
provide the following:
    (1) Site plans conforming to paragraphs (h)(5)(i) through 
(h)(5)(iv) of this section for proposed facilities to be used in 
contract performance.
    (2) Evidence of implementation of a safety program containing at 
least mandatory requirements described in Sec.  184.3.
    (3) General description of proposed contract facilities, including 
size, building layouts, construction details, and fire resistive 
capabilities.
    (4) Fire prevention program and available firefighting resources 
including local agreements or other documentation demonstrating 
coordination.
    (5) Copies of required licenses and permits or demonstration of the 
ability to obtain approvals necessary to support the proposed contract.
    (6) A safety history including mishap experience, safety survey or 
audit reports by insurance carriers or Federal, State, and local 
authorities, and any variances, exemptions or waivers of safety or fire 
protection requirements issued by Federal, state or local authorities.
    (7) Details of proposed operations and equipment to include process 
flow narrative/diagram, proposed facility or equipment changes, hazard 
analysis, and proposed procedures for all phases of AE operations.
    (8) Subcontractor information. (i) Identification of all 
subcontractors proposed for the AE work.
    (ii) Methods used to evaluate capability of subcontractor to comply 
with the requirements of this part.
    (iii) Methods used to manage subcontractor compliance.
    (f) Preoperational safety survey. The DoD reserves the right to 
conduct a preoperational survey after contract award of new items with 
limited contractor experience, after major new construction or major 
modifications, or after an AE mishap. When these situations occur, the 
contractor shall notify the ACO, sufficiently in advance, to provide 
the Department of Defense the opportunity to schedule and perform a 
preoperational survey.
    (g) Post-award contractor responsibilities. The contractor shall:
    (1) Comply with the requirements of this part and any other safety 
requirements contained within the contract.
    (2) Develop and implement a demonstrable safety program, including 
operational procedures, intended to prevent AE-related mishaps.
    (3) Designate qualified individuals to administer and implement 
this safety program.
    (4) Prepare, and keep available for review, all hazard analyses 
used to justify alternative methods of hazards control that differ from 
those recommended in this part.

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    (5) Provide access to facilities and safety program documentation 
to Government safety representatives.
    (6) Report and investigate AE mishaps in accordance with Sec.  
184.2.
    (7) Provide identification and location of subcontractors to the 
ACO for notification or approval in accordance with terms of the 
contract.
    (8) Establish and implement management controls to ensure AE 
subcontractors comply with paragraphs (g)(1) through (g)(7) of this 
section.
    (h) Site and construction plans. (1) Contractors must prepare site 
and construction plans for support of the pre-award process, and for 
any change in layout or construction potentially affecting Q-D incident 
to the contract. Contractors shall also maintain a current site map 
depicting Q-D relationships for all AE locations within the facilities.
    (2) When the place of performance of the contract is at a DoD-owned 
facility, site and construction plans shall be prepared and processed 
(content and staffing) in accordance with the requirements of DoD 
6055.9-STD, as well as, appropriate military service regulations 
contained within the contract.
    (3) For contractor-owned, contractor-operated (COCO) facilities, 
the contractor shall submit, through the ACO to the PCO, site and 
construction plans for all new construction or major modification of 
facilities for AE activities and for the facilities that may be exposed 
to AE hazards if improperly located. The contractor shall provide 
sufficient copies for the review process. The contractor shall not 
begin construction or modification of proposed facilities until 
receiving site and construction plan approval from the PCO through the 
ACO.
    (4) Minor new construction, changes, and modifications of existing 
AE facilities involving Hazard Class/Division (HC/D) additions and 
deletions or that add or remove small portable operating buildings and 
magazines may not require formal site plan submission. Minor applies to 
all changes that involve only 1.4 HC/D materials. Minor also applies to 
changes of other HC/D materials that do not increase the existing 
maximum credible event (MCE) for an AE facility or do not extend any 
quantity distance arcs beyond existing fragment, inhabited building, 
and public traffic route distance arcs for other nearby potential 
explosion sites (PES). When the contractor thinks a modification/change 
is minor, he shall notify the ACO and request a determination. The ACO 
shall make the final determination as to whether a formal site plan 
submission is necessary.
    (5) Site plans shall comply with the following:
    (i) Plans shall include maps and drawings which are legible, 
accurate, and of a scale which permits easy determination of essential 
details. For general layout of buildings, this is normally a scale of 1 
inch to 400 feet (or metric equivalent) or less. Site plans may require 
other-scaled drawings, which provide details of construction, structure 
relationships within the project area, barricades, or other unique 
details. Plans may also include pictures to illustrate details and 
videotapes of MCE testing data.
    (ii) Maps and drawings shall identify distances between all PESs, 
all exposed sites (ESs) within the facility, the facility boundary, any 
additional property under contractor control, ESs on adjacent property 
when applicable, public railways and highways, power transmission lines 
and other utilities.
    (iii) Plans shall identify and briefly describe all PESs and all 
ESs within any applicable fragmentation distance and/or inhabitable 
building distance of a PES. Site plans for major new construction or 
modification shall also identify and briefly describe all PESs whose 
inhabitable building distance are includes the proposed new or modified 
site.
    (iv) Plans shall include the maximum net explosive weight(s) (NEW) 
and the HC/Ds of all PESs and, when applicable, shall include MCE 
information and maximum NEW for each room or bay. Plans shall also 
include engineering or test data when substituting construction or 
shielding for distance to protect from fragmentation or overpressure.
    (v) Plans shall include a topographical map in sufficient detail to 
permit evaluation, when the contractor uses natural terrain for 
barricading to reduce fragment distance.
    (6) Construction plans for proposed facilities shall contain the 
information required in paragraphs (h)(5)(i) through (h)(5)(v) of this 
section and construction details of dividing walls, venting surfaces, 
firewalls, roofs, operational shields, barricades, exits, ventilation 
systems and equipment, AE waste disposal systems, lightning protection 
systems, grounding systems, processing equipment auxiliary support 
structures, and, general materials of construction, as applicable.


Sec.  184.2  Mishap investigation and reporting.

    (a) General. This section contains requirements for investigating 
and reporting mishaps involving AE.
    (b) Reporting criteria. The contractor shall investigate and report 
to the ACO and cognizant Defense Contract Management Agency (DCMA) 
contract safety specialist all mishaps involving ammunition or 
explosives that result in one or more of the following:
    (1) One or more fatalities.
    (2) One or more lost-work day cases with days away from work as 
defined by 29 U.S.C. 651-678.
    (3) Five or more non-fatal injuries (with or without lost 
workdays).
    (4) Damage to government property exceeding $20,000.
    (5) Delay in delivery schedule exceeding 24 hours. (This 
requirement does not constitute a waiver or amendment of any delivery 
schedule required by the contract.).
    (6) Contractually required notifications of mishaps other than in 
paragraphs (b)(1) through (b)(5) of this section; or
    (7) Any mishap that may degrade operational or production 
capability, or is likely to arouse media interest.
    (c) Mishap investigation requirements. Paragraph (e) of this 
section contains the elements of information which a basic 
investigation shall produce. Based upon the seriousness of the mishap 
and impact on munitions or munitions systems involved, the ACO or PCO 
may require an additional, more comprehensive investigation. The PCO 
retains the right to participate in contractor investigations, or to 
perform an independent DoD investigation. In the event the PCO directs 
DoD participation, or an independent DoD investigation, the contractor 
shall preserve the mishap scene, taking only those actions necessary to 
protect life and health, preclude further damage, or prevent access by 
unauthorized persons in order to preserve investigative evidence. The 
contractor shall obtain the PCO's permission to disturb the evidence, 
with the exception of paragraph (b)(2) of this section. Nothing in the 
reporting requirements contained in this part relieve the contractor of 
making other notifications required by Federal, State, or local 
requirements.
    (d) Telephone report. The contractor shall report any mishap 
described in paragraph (b) of this section by telephone to the ACO and 
cognizant DCMA contract safety specialist as soon as practicable, but 
not later than three hours after the mishap.
    (e) Written report. (1) The contractor shall submit a written 
report to the ACO and cognizant DCMA contract safety specialist by the 
end of the second business day after mishap occurrence.
    (i) Contractor's name and location.

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    (ii) Date, local time, and plant facility/location of the mishap.
    (iii) Type of mishap (explosion, fire, loss, other).
    (iv) Contract, subcontract, or purchase order.
    (v) Item nomenclature, hazard classification, lot number.
    (vi) Mishap narrative.
    (vii) Number of injuries, fatalities, degree of injuries. (viii) 
Description of property damage and cost.
    (ix) Quantity of energetic material involved (pounds, units, 
rounds).
    (x) Probable cause(s).
    (xi) Corrective action taken or planned.
    (xii) Effect on production.
    (xiii) Name, title or position, and phone number of person 
submitting the report.
    (xiv) Remarks.
    (2) The contractor shall provide to the ACO supplemental 
information to the initial report within 30 days of mishap occurrence.
    (f) Special technical mishap investigations and reports. When 
warranted by the circumstances of a mishap, the PCO may require a 
special technical investigation conducted by DoD personnel. The PCO may 
also direct the contractor to conduct a special technical 
investigation. In either case, the investigation report shall provide 
details such as fragmentation maps, photographs, more detailed 
description of events of the mishap, effects on adjacent operations, 
structural and equipment damage, Q-D drawings, detailed description of 
occurrence and related events, findings and conclusions. If the 
contractor performs the special technical mishap investigation, the 
contractor shall forward the report through the ACO to the PCO within 
60 days of the direction by the PCO to perform the investigation. Upon 
determination by the PCO that a DoD investigation is required, the PCO 
will immediately advise the contractor.


Sec.  184.3  General safety requirements.

    (a) General. This section provides general safety requirements for 
all AE operations addressed in this part. When these practices exceed 
or differ from local or national codes or requirements, the more 
restrictive shall apply.
    (b) Personnel and material limits. (1) Control of all locations or 
operations presenting real or potential hazards to personnel, property, 
or the environment is essential for safety and efficiency. Control 
measures include minimizing the number of personnel exposed, minimizing 
the duration of the exposure, and minimizing the amount of hazardous 
material consistent with safe and efficient operations.
    (2) All buildings, cubicles, cells, rooms, and locations containing 
AE shall have AE and personnel limits prominently posted. Include 
supervisors, production workers, and transient personnel when 
determining personnel limits. Posted personnel limits are not required 
in storage magazines, magazine areas, or transfer points.
    (3) All buildings, cubicles, cells, rooms or locations containing 
AE shall have prominently posted limits for the quantities of AE 
permitted. The posted limits shall not exceed the quantity stipulated 
in the site plan, and shall accurately reflect current process 
requirements. Post AE limits in storage magazines when the limit 
differs from that for other magazines in the block, or when 
circumstances prevent the limit from being readily apparent. It is not 
required to express AE limits in units of weight or in the number of 
items. Express limits in terms of trays, boxes, racks, or other units 
more easily observed and controlled.
    (c) Standard operating procedures (SOP). (1) Clearly written 
procedures are essential to avoid operator errors and ensure process 
control. Therefore, before commencing manufacturing operations 
involving AE, qualified personnel shall develop, review, and approve 
written procedures.
    (2) Preparation. The contractor shall prepare and implement written 
procedures which provide clear instructions for safely conducting AE 
activities. The use of controlled tests is an acceptable method for 
developing and validating SOPs. SOPs shall include the following:
    (i) The specific hazards associated with the process.
    (ii) Indicators for identifying abnormal process conditions.
    (iii) Emergency procedures for abnormal process conditions or other 
conditions which could affect the safety of the process.
    (iv) Personal protective clothing and equipment required by process 
personnel.
    (v) Personnel and AE limits.
    (vi) Specific tools permitted for use by the process operator.
    (vii) The chronological sequence of job steps the operator is to 
follow in performing the work.
    (viii) Procedures for disposing of any scrap and waste AE.
    (3) Dissemination. Personnel involved with AE processes, and 
personnel who maintain AE equipment, shall have written operating 
procedures readily accessible.
    (4) Training. Personnel shall receive appropriate training before 
performing work involving exposure to AE. The training shall include 
emphasis on the specific safety and health hazards, emergency 
operations including shutdown, and safe work practices applicable to 
the employee's job tasks. The contractor shall ascertain that each 
employee involved in an AE process has received and understood the 
training. The contractor shall prepare a record that contains the 
identity of the employee, the date of training, and the means used to 
verify that the employee understood the training.
    (5) Emergency procedures. The contractor shall instruct employees 
on procedures to follow in the event of electrical storms, utility or 
mechanical failures, equipment failures, process abnormalities, and 
other emergencies occurring during the manufacturing, handling, or 
processing of AE.
    (6) Revalidation. Qualified personnel shall review SOPs on a 
regular basis. The managing authority shall change and validate SOPs as 
often as necessary to reflect improved methods, equipment 
substitutions, facility modifications, or process revisions.
    (d) Storage in operating buildings. (1) The contractor may store 
limited quantities of hazardous materials, other than AE materials, 
which are essential for current operations in an operating building.
    (2) The contractor shall store AE materials that exceed minimum 
quantity necessary for sustained operations in a service magazine 
located no closer than the intraline distance (ILD) (based on the 
quantity in the magazine) from the operating building or area. If ILD 
distance is not available for a separate service magazine, the 
contractor may designate storage locations within the operating 
building. Designated storage locations shall preclude immediate 
propagation from the operational location to the storage location. The 
quantity of AE material in the internal storage location shall not 
exceed that needed for one half of a work shift. The contractor should 
consider personnel exposure, structural containment afforded, and the 
venting ability of the proposed storage location when determining where 
to locate a designated storage location. When storage containers 
completely contain all fragments, debris, and overpressure, AE material 
may be stored without regard to Q-D requirements.
    (3) At the end of the workday, personnel should remove all AE 
material from processing equipment and store it in an appropriate 
magazine or designated storage location. If operationally required, 
personnel may store in-process AE materials in the

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building during non-operating hours provided the physical 
characteristics and stability of the AE materials are not degraded, and 
the AE material would not compromise the safety of the process 
equipment or personnel when the process is restarted.
    (4) The contractor may use a separate enclosed room or bay in an 
operating building specifically adapted for the interim storage of 
production items awaiting the results of testing before final pack-out. 
The room or bay must afford the equivalent of service magazine distance 
protection to other parts of the building, and ILD to other buildings. 
Such a room or bay is limited to its defined and designed function and 
items, but is not subject to the four-hour supply limitation for the 
building or the ultimate pack-out operation.
    (e) Housekeeping in hazardous areas.
    (1) The contractor shall keep structures containing AE clean and 
orderly.
    (2) Explosives and explosive dusts shall not accumulate on 
structural members, radiators, heating coils, steam, gas, air or water 
supply pipes, or electrical fixtures.
    (3) Written procedures shall include instructions for the removal 
of spilled material.
    (4) Floor cleaning methods shall not create an ignition hazard or 
alter the conductive ability of floors in AE areas, nor should they 
result in an environmental contamination potential.
    (5) Cleaning methods for AE processing equipment shall not result 
in any foreign material or AE remaining in the equipment.
    (f) Precautions for maintenance and repairs to equipment and 
buildings. (1) The contractor shall examine and test all new or 
repaired AE processing equipment prior to placing the equipment in 
service in order to ensure that it is safe to operate.
    (2) Before proceeding with maintenance or repairs to AE processing 
equipment, contractor personnel shall decontaminate the equipment to 
the degree necessary to perform the work safely. The contractor shall 
protect maintenance personnel from the effects of a reaction resulting 
from AE material in or on other parts of the equipment. Contractor 
personnel shall tag AE processing equipment before proceeding with 
repairs. The tag shall identify the decontaminated parts of the 
equipment, and those parts that contain AE.
    (3) The contractor shall have SOPs for maintenance personnel 
performing work on AE equipment or performing building maintenance, 
repair, or modification activities in AE areas. The SOPs shall include 
a provision for inspecting equipment after maintenance work to ensure 
no tools or foreign materials remain in AE equipment. The SOPs shall 
identify the specific tools required to perform work on equipment which 
may contain explosive residues or areas which could have an explosive 
atmosphere.
    (4) Before performing any building repair, modification or 
maintenance activity, the contractor shall ensure the removal of all AE 
materials from areas that may pose a hazard. The contractor shall also 
ensure the decontamination of all places where AE material could 
accumulate, such as, equipment, crevices, vents, ducts, wall cavities, 
pipes and fittings.
    (g) Operational shields. (1) The purpose of operational shields is 
to prevent propagation of AE material from one AE operation or location 
to another, protect facilities and equipment, and provide personnel 
protection. Shields used for these purposes require an evaluation to 
determine their suitability for their intended purpose. All AE 
operations and processes require a hazard assessment prior to work 
performance to determine the type of hazard involved, the level of risk 
associated with the AE material or item, and the corresponding level of 
protection required.
    (2) The primary hazards that accompany explosions and deflagrations 
are blast overpressure, fragmentation (primary and secondary) and 
thermal effects. The hazard assessment shall consider these hazards and 
the quantity of AE materials, initiation sensitivity, heat output, rate 
of burning, potential ignition and initiation sources, protection 
capabilities of shields, various types of protective clothing, fire 
protection systems, and the acute and chronic health hazards of vapors 
and combustion products on exposed personnel.
    (3) When the hazard assessment indicates an unacceptable 
probability of explosion or deflagration, conduct operations or 
processes remotely. When an analysis of the hazard assessment indicates 
the hazards associated with an explosion or deflagration are 
controllable by using operational shields, the contractor shall design, 
install, and use shields which effectively protect personnel from the 
hazards. Shields complying with MIL-STD-398 are acceptable protection.
    (4) The contractor shall test operational shields under conditions 
that simulate the operational environment. AE materials or items used 
in the test shall correspond to those that may be involved in a maximum 
credible event (MCE), plus 25 percent. The contractor shall maintain 
records of the test that demonstrate the shields will function as 
planned. Analysis rather than testing of shields may be acceptable on a 
case-by-case basis.
    (5) When the doors of AE processing equipment function as 
operational shields, interlocking devices are required to prevent the 
operator from opening the door while the equipment is in operation.
    (h) Protective clothing. (1) All AE operations require a hazard 
assessment to determine the need for protective clothing and personal 
protective equipment. The assessment shall include an evaluation of all 
hazards and factors contained in paragraph (g)(2) of this section.
    (2) The contractor shall provide a changing area for employees who 
must remove their street clothes to wear protective clothing, such as 
explosive plant clothing, anti-contamination clothing, impervious 
clothing, and so forth. To avoid exposing personnel not involved in AE 
operations to unnecessary risks, employees shall not wear or remove 
protective clothing from the premises. Employees shall not wear any 
static producing clothing in areas where static electricity is a 
hazard.
    (3) Explosives plant clothing, generally referred to as powder 
uniforms, shall have nonmetallic fasteners and be easily removable.
    (4) When sending explosives-contaminated clothing to an off-plant 
laundry facility, the contractor is responsible for informing the 
laundry of the hazards associated with the contaminants and any special 
laundering or disposal requirements.
    (i) Material handling equipment. (1) The contractor shall not 
refuel gasoline, diesel or liquefied petroleum gas (LPG) powered 
equipment inside buildings containing AE. Refueling shall take place at 
least 100 feet from structures or sites containing AE. Doors and 
windows through which vapors may enter the building shall not be open 
during refueling. Position refueling vehicles at least 100 feet from 
structures or sites containing AE during refueling.
    (2) Gasoline-, diesel- or LPG-powered equipment shall not be stored 
in buildings, loading docks, or piers containing AE. The contractor 
shall store gasoline-, diesel-, and LPG-powered equipment at the 
appropriate fire protection distance from buildings containing AE.
    (3) Gasoline, diesel, and LPG powered equipment shall have spark 
arrestors. The contractor shall perform and document inspections of the 
exhaust and electrical systems of the equipment

[[Page 16043]]

as necessary to ensure that the systems are functioning within the 
manufacture's specifications. The contractor shall maintain 
documentation of the inspections for a period of one year.
    (j) Parking of privately owned vehicles. (1) Control of parking of 
privately owned vehicles within an AE establishment minimizes fire and 
explosion hazards and prevents congestion in an emergency.
    (2) Parking lots serving multiple PESs shall not be closer than the 
ILD from each PES. Parking lots serving a single PES shall not be 
closer than 100 feet to the associated facility to protect it from 
vehicle fires, and shall be at least public traffic route distance from 
unassociated PESs. Parking lots for administration areas shall be 
located at public traffic route distance from all PESs.
    (3) Vehicles shall not obstruct access to buildings by emergency 
equipment or personnel.
    (k) Ignition sources in hazardous areas. The contractor shall not 
permit any nonessential ignition sources in operating buildings.
    (l) Operational explosives containers. (1) Containers shall be 
compatible with the material they contain.
    (2) Containers used for intraplant transportation or storage of 
process explosives and energetic materials shall not leak. Because of 
their fragility and potential for fragmentation, glass containers are 
not acceptable.
    (m) Intraplant rail transportation. (1) The contractor shall 
develop written procedures to ensure safe and efficient rail movement 
of AE. The SOPs shall include information covering the inspection of 
the engine, car mover, and cars, normal and emergency operating 
procedures for the engine and car mover, AE loading and unloading 
procedures, and emergency procedures including fire fighting.
    (2) Railcars positioned for loading shall have their brakes engaged 
to prevent movement. Contractor personnel shall inspect each railcar 
before loading to ensure it is suitable to carry the specific AE cargo. 
Contractor personnel shall check the cargo to ensure it is stable and 
secure, and close the railcar doors before car movement. If using an 
engine to move railcars, the contractor shall ensure that personnel 
have connected the air brakes of the railcars in sequence to the 
engine. If moving a railcar with a car mover the contractor shall 
station an individual at the hand brake of the railcar.
    (3) A single parked railcar shall have the hand brakes set and the 
wheels chocked. When more than one railcar is parked, personnel shall 
set hand brakes on enough railcars to ensure the cars will not move. 
Personnel shall set hand brakes on the downgrade end of a group of 
parked railcars. Do not rely on the automatic air brakes to hold parked 
railcars.
    (4) Contractor personnel shall avoid rough handling of railcars. 
Personnel shall not disconnect railcars containing AE from each other 
or a locomotive while in motion. Personnel shall couple railcars gently 
in order to avoid damaging the AE cargo or shipping containers. 
Disconnected railcars shall not strike railcars containing AE.
    (5) The contractor shall maintain all rolling stock used for 
intraplant transportation of AE in a safe and good working condition.
    (6) Portable transmitters and railroad locomotives equipped with 
two-way radios shall not transmit when passing AE operating buildings 
where electro-explosive devices are in use. The contractor shall 
determine minimum safe distances based on radio frequency and power 
output of the transmitter.
    (n) Intraplant motor vehicle transportation of AE. (1) The 
contractor shall develop written procedures for the safe transportation 
of AE in motor vehicles. The SOP shall include procedures for vehicle 
inspection, vehicle operation, loading and unloading AE materials, and 
emergency procedures, including fire fighting.
    (2) The operator responsible for transporting AE material shall 
perform a daily inspection of the vehicle before transporting 
materials. The operator shall verify that the fire extinguisher is 
charged and in working order, there are no fuels or other fluid leaks, 
and that brakes, tires, steering, and other equipment are in good 
operating condition. Before transporting AE, the operator shall inspect 
the cargo compartment to ensure it does not contain any residual AE 
material or any object which could present a hazard to the cargo.
    (3) When loading or unloading AE, the operator shall shutoff the 
vehicle's engine, unless the engine is required to provide power to 
equipment for loading or unloading. The operator shall engage the 
emergency brake and use wheel chocks when the vehicle could move during 
loading or unloading. The operator shall stabilize and ensure the load 
is secure to prevent damage to containers or their contents. The 
operator shall not transport AE material in the passenger compartment 
of the vehicle.
    (4) The vehicle operator shall understand and follow established 
procedures involving a vehicle fire, breakdown, accident, damaged or 
leaking containers, and spilled material.
    (5) Transportation containers shall not allow the contents to leak 
or spill in transit.
    (6) Non-sparking material shall cover the cargo compartment when 
transporting AE in containers capable of exposing their contents if 
damaged.
    (7) Motor vehicles transporting AE within the establishment 
boundaries but outside the AE area shall bear at least two placards. 
Placards based on the fire division symbols discussed in Sec.  184.10, 
``Fire Protection,'' are acceptable. Motor vehicles or equipment with 
internal combustion engines, used near explosives scrap, waste, or 
items contaminated with explosives shall have exhaust system spark 
arresters and carburetor flame arresters (authorized air cleaners).
    (8) The contractor shall maintain vehicles and material handling 
equipment used to load and transport AE in a safe operating condition.
    (9) Batteries and wiring shall be located to prevent contact with 
containers of AE material.
    (o) Inspection of AE mixing equipment. (1) The contractor shall 
establish a preventative maintenance program which includes the 
inspection of all AE mixing equipment on a periodic basis. The SOP for 
the inspection shall include criteria for inspecting the blades to bowl 
clearances, alignment of the blades and bowl, and detection of any 
distortion of the blades or bowl. The inspection procedures shall also 
include instructions for checking critical drive system components for 
wear, damage or misalignment. The procedures shall include criteria for 
determining that associated equipment used to control the mixer is 
functioning as designed. The contractor shall maintain a record of all 
inspections. After performing maintenance of the equipment, the 
contractor shall run the equipment under load to ensure it is safe to 
operate.
    (2) The SOPs for operating mixing equipment shall include 
instructions for inspecting specific equipment components before each 
use.
    (p) Facility requirements. (1) Buildings. The design, construction 
techniques, process layout, and siting of AE buildings are important 
considerations in explosives safety and directly influence quantity 
distance (Q-D) requirements and the degree of exposure to personnel, 
equipment, and facilities. Construction features which limit the amount 
of explosives involved, attenuate the resulting blast overpressure or 
thermal radiation, and reduce the quantity and range of

[[Page 16044]]

hazardous fragments and debris will help to minimize the effects of an 
explosion. Incorporating Q-D criteria, when locating an exposed site 
(ES) in relation to a potential explosive site (PES), will reduce the 
amount of damage and injuries in the event of an incident.
    (2) Building exteriors. The contractor should design and erect AE 
buildings with the ability to allow for the venting of an internal 
explosion without collapsing. The use of lightweight materials in 
exterior wall and roof sections designed to vent the effects of an 
explosion will help reduce the number of large fragments. Exceptions 
from using lightweight materials include earth-covered magazines, 
containment type structures, firewalls, substantial dividing walls, 
special roof loadings, and walls and roofs used for external 
overpressure protection. Non-combustible exterior wall and roof 
coverings of operating buildings help prevent the spread of fire from 
one area of a building to another and from building to building.
    (3) Interior walls, roofs, and ceilings. (i) Non-combustible 
material is preferred for the interior surfaces of buildings. The 
contractor should treat or cover exposed combustion supporting building 
materials with fire retardant material.
    (ii) Where hazardous locations exist, interior surfaces shall be 
smooth, free from cracks, crevices and openings which may create a 
hazardous condition. This is important to prevent the accumulation or 
migration of explosive dust and vapors which could result in an 
incident. The National Fire Protection Association (NFPA), Standard 70 
\2\ provides criteria for determining if a location is hazardous.
---------------------------------------------------------------------------

    \2\ Obtain NFPA publications from the National Fire Protection 
Association at https://www.nfpa.org/catalog/home/index.asp.
---------------------------------------------------------------------------

    (iii) The contractor should use hard gloss, easily cleanable, paint 
on painted surfaces.
    (iv) Periodically clean any surface where explosive dust could 
accumulate. Establish cleaning schedules on information obtained from 
the job hazard analysis.
    (v) Do not use suspended ceilings in hazardous locations.
    (4) Floors and work surfaces. (i) Locations where exposed 
explosives or hazardous concentrations of flammable vapor or gas are 
present require non-sparking floors and work surfaces.
    (ii) Sec.  184.12 provides requirements for conductive non-sparking 
floors and work surfaces.
    (iii) Floors and work surfaces require periodic cleaning to prevent 
the accumulation of energetic materials. In addition, all conductive 
and non-sparking floors and work surfaces require preventative 
maintenance to ensure their functional integrity.
    (5) Substantial dividing walls. The contractor shall design and 
construct substantial dividing walls to prevent simultaneous detonation 
of explosives on opposite sides of the wall. The design and 
construction shall meet the criteria contained in Army TM 5-1300, Navy 
NAVFAC P-397, or Air Force AFR 88-22 (different designations for the 
same publication).
    (6) Exits and doors. (i) All AE buildings require adequate exits 
and doors. NFPA Standard No. 101, ``Life Safety Code,'' provides 
information concerning exits and doors.
    (ii) NFPA Standard No. 80, ``Standard for Fire Doors, Fire 
Windows,'' provides information on the selection and installation of 
fire doors and windows.
    (iii) No AE hazards shall occupy space between an operator and an 
exit.
    (7) Safety chutes. Multi-storied locations where rapid egress is 
vital and not otherwise possible require safety chutes.
    (8) Passageways. (i) Weather-protected passageways and ramps for 
travel between buildings or magazines should include features to help 
prevent fire from spreading from one building to another. Fireproof 
construction materials, fire stops, fire doors, and fire suppression 
systems aid in preventing the spread of fire.
    (ii) The incorporation of weak sections, openings, or abrupt change 
in direction of passageways will aid in the prevention of funneling the 
explosion forces from one building to another.
    (9) Roads and walkways. (i) Only roads servicing a single magazine 
or AE processing building, including its service facilities, may dead 
end at the magazine or building.
    (ii) Hard surfaced roads and walkways at the entrances to or 
between adjacent operating buildings containing AE will help reduce the 
amount of foreign material tracked into the building by personnel.
    (iii) Avoid a road system which requires personnel to pass through 
an AE area when traveling from one area to another.
    (10) Windows and skylights. (i) Inhabited building distances do not 
protect against glass breakage and the hazards of flying glass. 
Buildings separated by inhabited building distance should not have 
windows or other glass surfaces exposed to PESs.
    (ii) Minimize personnel hazards from glass breakage by means such 
as building orientation and/or keeping the number of exposed glass 
panels and panel size to a minimum. When window panels are necessary 
and risk assessment determines a glass hazard will be present, blast 
resistant windows must be used. The framing and/or sash of such panels 
must be of sufficient strength to retain the panel in the structure.
    (11) Hardware. (i) AE operations and hazardous locations require an 
evaluation to determine the safest type of hardware and fasteners to 
use in order to reduce the risk of an accidental ignition. Consider 
using non-sparking hardware and fasteners if they will meet the design 
parameters of the intended application. Depending on the potential 
hazard, a locking device or some other installation technique shall 
retain the hardware and fasteners securely in place. This will prevent 
the hardware and fasteners from becoming loose, entering process 
equipment and creating a spark or pinch point.
    (ii) The contractor should avoid installing hardware, pipes, ducts, 
and other items on blowout panels in order to prevent the materials 
from becoming secondary fragments. If it is necessary to install items 
on blowout panels, select items made of materials which will not yield 
heavy fragments in an explosion.
    (12) Ventilation systems. (i) Well-designed ventilation systems 
reduce personnel exposures to airborne contaminants and prevent the 
accumulation of flammable or explosive concentrations of gases, vapors 
or dusts. A local ventilation system, which removes the gases, vapors, 
or dusts at the source, is more effective than a general ventilation 
system.
    (ii) A ventilation system is required in areas of buildings 
generating potentially explosive dusts, gases or vapors. Testing, 
inspection, and maintenance of ventilation systems used for contaminant 
control require documentation.
    (iii) Exhaust fans through which combustible dust or flammable 
vapor pass shall have nonferrous blades or a casing lined with 
nonferrous material. The electrical wiring and equipment of the system 
should comply with provisions of NFPA Standard No. 70, ``National 
Electrical Code''. Bonding and grounding of the entire system is 
required.
    (iv) A slight negative pressure is required in rooms where AE 
operations generate explosive dust.
    (v) NFPA Standard No. 91, ``Standard for Exhaust Systems for Air 
Conveying of Vapors, Gases, Mists, and Noncombustible Particulate 
Solids,'' provides standards for exhaust systems.

[[Page 16045]]

    (13) Steam for processing and heating. (i) Steam used to heat 
buildings containing explosives shall not exceed 228 [deg]F (108.9 
[deg]C) or have a pressure greater than 5 psi (34.48 kPa).
    (ii) Process steam shall not exceed 249.5 [deg]F (120.8 [deg]C), or 
exceed 15 psi (103.43 kPa). Steam pressure greater than 15 psi (103.43 
kPa) requires procuring contracting officer (PCO) approval.
    (iii) The surface temperature of steam and hot water pipes in 
contact with combustible materials shall not exceed 160 [deg]F (71 
[deg]C). Pipes with an ambient temperature greater than 160 [deg]F (71 
[deg]C) shall not contact combustible materials. An insulating pipe 
covering capable of reducing the surface temperature of the covering to 
160 [deg]F (71 [deg]C) or less is acceptable.
    (iv) In AE handling or storage locations where resistance to ground 
is high, ground steam and hot water lines where they enter the 
building.
    (v) When using a reducing valve, consider installing a relief valve 
on the low-pressure piping. The throttling action of reducing valves 
requires a positive means to prevent the production of superheated 
steam.
    (14) Tunnels. Tunnels between buildings that contain AE shall 
incorporate features that resist the shock wave of an explosion. This 
is important in order to minimize the possibility of an explosion in 
one building from affecting the operations in the other building. For 
further information on tunnels go to DoD 6055.9-STD.\3\
---------------------------------------------------------------------------

    \3\ See footnote 1 to Sec.  184.1(d)(1).
---------------------------------------------------------------------------

    (q) Quantity-distance (Q-D) requirements. (1) Minimum Q-D 
requirements are contained in DoD 6055.9-STD, DoD Ammunition and 
Explosives Safety Standards.
    (2) For AE work involving an MCE of 0.25 kg (0.55 lbs) or less of 
HD 1.1 materials, the use of the separation distances listed in Table 1 
to Sec.  184.3 are acceptable for meeting minimum Q-D requirements.

     Table 1 to Sec.   184.3.--Minimum Q-D Requirements for Small Quantities of Hazard Division 1.1 Material
----------------------------------------------------------------------------------------------------------------
                                        Inhabited building and    Public traffic route    Intraline and fragment
         Net explosive weight             fragment distance      and fragment distance           distance
----------------------------------------------------------------------------------------------------------------
Less than 0.003 kg (0.0066 lb).......  0......................  0......................  0.
0.003 kg-0.01 kg (0.0066 lb-0.022 lb)  5 m (16.5 ft)..........  3 m (9.9 ft)...........  2 m (6.6 ft).
0.01 kg-0.25 kg (0.022 lb-0.55 lb)...  15 m (49.5 ft).........  9 m (29.7 ft)..........  5 m (16.5 ft).
----------------------------------------------------------------------------------------------------------------

Sec.  184.4  Quantity-distance and siting.

    Refer to DoD 6055.9, Chapter 9 for guidance.


Sec.  184.5  Hazard classification, storage principles, and 
compatibility groups.

    Please refer to DoD 6055.9, Chapter 3 for guidance.


Sec.  184.6.  Electrical safety requirements for AE facilities.

    (a) General. Initiation systems often use the controlled input of 
electrical energy to initiate explosive mixtures and compounds, which 
start an explosive train. The uncontrolled release of electrical energy 
in explosive atmospheres or near explosives and explosive-loaded 
articles can result in unintended initiation and serious mishaps. 
Electrical energy manifests itself in many forms (e.g., standard 
electrical installations, lightning, electrostatic discharge, 
electrical testing) and with various intensities which require special 
precautions. This chapter contains minimum electrical safety 
requirements for existing, new, or modified explosives facilities and 
equipment.
    (b) Electrical installations. (1) National Fire Protection 
Association (NFPA) Standard No. 70 and this section are minimum 
requirements for areas containing explosives. NFPA Standard No. 70 does 
not specifically address explosives, but it does establish standards 
for the design and installation of electrical equipment and wiring in 
atmospheres containing combustible dusts and flammable vapors and 
gasses which, in general, are comparably hazardous. NFPA Standard No. 
70 (Article 500) defines ``hazardous locations'' according to the 
hazard presented by electrical equipment installed in environments 
where flammable gases or vapors, combustible dusts or flyings may 
exist. The presence of AE may or may not result in rating a particular 
location as a ``hazardous location.'' The following exceptions shall be 
used by DoD contractors when applying the NFPA Standard No. 70 
definitions of Class I, Division 1, and Class II, Division 1 hazardous 
locations:
    (i) Classify areas containing explosive dusts or explosive 
substances which may produce dust capable of suspension in the 
atmosphere as Class II, Division 1 hazardous locations.
    (ii) Classify areas where explosive sublimation or condensation may 
occur as both Class I Division 1 and Class II Division 1 hazardous 
locations.
    (iii) Exceptions are extraordinarily hazardous explosive 
substances, such as nitroglycerin (NG), which require special 
consideration, including physical isolation from electric motors, 
devices, lighting fixtures and the like.
    (2) Multiple classifications. In some potential explosion sites 
(PES) (e.g., powder blending with solvents), hazards resulting from 
both dusts and flammable vapors may exist. In these cases, it is 
necessary for that area to have a dual, or multiple, classification. 
Use only electrical equipment listed by Underwriters Laboratories (UL) 
or other recognized testing laboratory as suitable for use in all 
classes of hazardous locations.
    (3) Change of classification. The specific processes performed in 
operating buildings and magazines dictate the requirements for 
electrical equipment installation. If functions performed in the 
facility change, responsible personnel shall inspect, approve, or 
reclassify the hazardous locations.
    (4) Alternate power source. Facilities shall have an alternate 
power source for special processes and operations requiring a 
continuous supply of power, whenever the loss of power will result in a 
more hazardous condition.
    (5) Portable engine-driven generators. The exposed, non-current-
carrying, metallic frame and parts shall be electrically grounded. In 
addition, observe the following requirements when supplying power to 
magazines or explosives operating facilities.
    (i) Place generating units at least 50 ft (15.2 m) from magazines 
or hazardous (classified) locations.
    (ii) Keep the ground area between and around the generator and the 
NFPA Standard No. 70 hazardous (classified) location clear of debris 
and other combustible materials.
    (iii) The exhaust from the generator shall not impinge on grass or 
any other combustible material.
    (iv) Position the power cord connecting the generator to the load 
to

[[Page 16046]]

prevent trucks or personnel from running over or otherwise damaging the 
cord.
    (v) Do not use cable-to-cable splices within a magazine, explosive 
operating facility, or other NFPA Standard No. 70 hazardous 
(classified) location. Use only three-wire, three-prong, approved 
service type plugs and connectors.
    (vi) Refer to Sec.  184.3(i)(1) for refueling procedures.
    (6) Electric supply systems. Electrical and explosives hazards may 
mutually exist when PES are in close proximity to electric supply 
lines. To protect these hazards from each other, the following 
separation requirements shall apply:
    (i) Separate overhead service lines from a PES of combustible 
construction or a PES in the open by the distance between the poles or 
towers supporting the lines, unless an effective means is provided to 
ensure that energized lines cannot contact the facility or its 
appurtenances if they are severed. Four acceptable alternatives are 
cable trays and messenger lines, a ground-fault circuit-interrupter 
which causes a disconnecting means to open all ungrounded conductors of 
the faulted circuit, weighted triangle line separators or similar 
weights which ensure broken lines fall straight down away from PES, and 
constructed physical barriers.
    (ii) Separate electric distribution lines carrying less than 69 kV, 
the tower or poles supporting those lines, and unmanned electrical 
substations from PES by public traffic route distance (PTRD).
    (iii) Separate electric transmission lines carrying 69 kV or more 
and the tower or poles supporting them from PES by:
    (A) Inhabited building distance (IBD) if the line in question is 
part of a grid system serving a large area off the establishment.
    (B) PTRD if loss of the line does not create serious social or 
economic hardships. (Note: Base PTRD and IBD on airblast overpressure 
only. Fragment distances shall not apply.)
    (C) Distances in accordance with paragraph (b)(6)(1) of this 
section when the line(s) in question can be interrupted without loss of 
power (i.e., other lines or networks exist for rerouting power).
    (iv) Avoid locating permanent electric installations in NFPA 
Standard No. 70 Class I or Class II hazardous locations. When practical 
operating reasons prevent locating permanent electrical installations 
outside of hazardous locations, or require the use of portable 
electrical equipment (e.g., lighting equipment) in hazardous locations, 
contractors shall only install or use electrical equipment approved for 
the National Electric Code (NEC) defined ``hazardous location'' and 
listed by Underwriters Laboratories (UL) or other nationally recognized 
testing agencies.
    (c) Primary electric supply. The primary electric supply to an 
entire explosives area should be arranged to allow cutting off the 
supply by remote switches located at one or more central points away 
from the area.
    (d) Ventilation. Equip exhaust fans, through which combustible dust 
or flammable vapor pass, with nonferrous blades, or line the casing 
with nonferrous material. Motors shall meet the proper NEC class for 
the hazard (NFPA Standard No. 70). Clean and service exhaust systems on 
a regular schedule. Bond and ground the entire system.
    (e) Lightning protection. When lightning protection systems are 
installed, the installation, inspection, and maintenance shall comply 
with the NFPA Standard No. 780, at a minimum. Typically, six month 
visual tests and 24-month electrical tests of installed systems are 
acceptable.
    (f) Static electricity and grounding. (1) Two unlike materials (at 
least one of which is non-conductive) produce static electricity due to 
contact and separation. Contact creates a redistribution of charge 
across the area of contact and establishes an attractive force. 
Separation of the materials overcomes these attractive forces and sets 
up an electrostatic field between the two surfaces. If no conducting 
path is available to allow the charges to equalize on the surfaces, the 
voltage difference between the surfaces can easily reach several 
thousand volts as they separate.
    (2) The potential hazard of static electricity arises when an 
accumulated electrical charge subsequently discharges as a spark in the 
presence of hazardous atmospheres, flammable vapors, dusts, exposed 
sensitive explosives, or electro-explosive device (EED). Electrostatic 
discharge (ESD) does not present a substantial hazard during the 
handling of most bulk explosive substances if the explosives are in 
approved containers. It also does not present a hazard near explosives 
totally contained and unexposed within loaded articles. It is not 
possible to prevent the generation of static electricity entirely. 
Elimination of potential ESD hazards requires proper grounding to 
dissipate static charges before they accumulate to dangerous levels. 
The NFPA, UL and the U.S. Department of Commerce publish detailed 
discussions of the hazards of static electricity and ways of reducing 
it. Where static spark discharge may be hazardous, NFPA Standard No. 
77, shall apply, except as otherwise specified.
    (3) Static ground system. A static ground system consists of one or 
more electrodes in contact with the earth and a conductor (i.e., metal 
wire) bonded to the electrode and routed throughout the protected 
facility.